Hello,
My 2002 F-250 5.4L gasser, 4WD CCLB at 234,000 miles has a head gasket issue. Yep, burning some coolant. The question I have as I contemplate getting it serviced. Remove both heads and give it a good servicing. Timing chains, tensioners, the works. S&J has engines for the 5.4L around $3,500 ish. There is another (performance engines, I think) for slightly less.
Question 1: Can the 5.4 be replaced with a more powerful engine? Without really changing much else?
Question 2: Refurbished or remanufactured? What's the difference?

 

There have been a few members who swap to a 2V 6.8L V-10. That would involve changing or upgrading the transmission, engine wiring harness and engine computer. That will get you +50HP and +75 foot/pounds.

A Cummins swap is always popular, but the Cummins engines are becoming expensive. Kits are being offered to use almost any transmission, Ford, GM or Ram.

Otherwise, replacing your engine and upgrading your differential ratios is always an option.

 

Redford has the basics of it covered. The easiest swap without a power adder is probably swapping to a 6.8 V10, but as said, you'll need PCM, trans, and harness. Possibly exhaust modifications. Most other things should remain the same.

Diesel is going to be the most expensive, as you also need to swap the ENTIRE fuel system, and it would probably be a good idea to swap the instrument cluster too (glow plug light and possibly boost gauge).

You could also look into having your 5.4 rebuilt with better internals, and adding a turbo or supercharger to it. You'll spend a lot on better internals and the power adder, but you won't have to source a wiring harness, PCM, or transmission (though you'll likely need a tuner, and it wouldn't hurt to have your trans gone through and possibly beefed up too).

 

Man I just did an engine swap on my 03 5.4 2v and explored literally all these different options myself.
If you have any questions about removal, need pics, I took a ton doing it for reference, message me or comment here, I'd be happy to help.

All started with will my timing chain is slapping pretty good, but it had 195,xxx and been worked pretty good till that point. Then you do a timing chain you might as well doing a nicer higher pressure oil pump, but if your into it that far why not just pull it and do an engine rebuild because your manifolds that have been leaking for the last 5 years are also needing attention. Sorta snowballed for me...... hahah

Question 1, Not really. If you upgrade the power your gonna need a stronger tranny to compliment it. The V-10 from my understandings on here were upgraded to handle more than the V-8's
You could do a Heavy Duty torque convertor though with the engine out.

Question 2.
Refurbished or referenced as rebuilt is literally only replacing what only needs to be replaced to make it work again.
More an efford to try and save a few bucks.
Reman is completely torn down & rebuilt with new OEM parts all the way back up.

They explain it here.
https://www.sandjengines.com/promos/...ctured-engines

I went with a 5.4 from S&J and literally now have only 58 miles on it after install. For only 400$ I had them all do a port & polish on intake and exhaust valves.
I think when it was all said & done it was like 4400$? ish or something like that, they even gave me a vet discount and dropped the price a couple hundred for me.

My trucks basically mechanically fully rebuilt at this point and love it. Prices are to insane to justify buying anything for awhile for me.
Good luck!

 

To add to this I considered a diesel swap as we have a very quite well known diesel shop that has done quite a few for people around here.
They answered all my questions & were extremely helpful about it.

Basically at the time they said we literally cant get our hands on a 12V that we would need for your truck. We simply cannot find anything to buy and we look and buy anything we can just
to have it on hand for future customers. They did have a 24V but you run into quite a headache of electrical conversions I didn't want to deal with doing that. They also said the price of just finding blocks or
donor cars is going up along with that. If I could of found a donor car for them to use with a 12v that would of also been an option. Seeing as how well that 5.4 did for me all the years it ran great I ended up sticking with
a 5.4 reman.